Drum-type washing machine and bearing housing structure thereof

ABSTRACT

A drum type washing machine including a tub installed in a cabinet is disclosed. The drum type washing machine includes a drum performing washing, a motor rotating the drum, bearing housings having bearings to support a rotation shaft, a suspension connected to the bearing housings and the cabinet to mitigate vibration generated during rotation of the drum, a bracket installed to the bearing housings to form the rear side of the tub, and a gasket installed between the bracket and the tub to seal the tub and to prevent vibration from being transmitted from the bracket to the tub. Volumes of the tub and the drum can be easily increased without increasing the volume of the cabinet. Even when the volume of the washing machine is changed, only one of the tub and the bearing housings, which is not applicable to the drum type washing machine having the changed washing capacity, is selectively replaced. Thus parts can commonly used in various drum type washing machine having different volume.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of prior U.S. patentapplication Ser. No. 12/198,269 filed Aug. 26, 2008, which is acontinuation application of prior U.S. patent application Ser. No.11/165,332 filed Jun. 24, 2005 now U.S. Pat. No. 7,607,326, which claimsthe benefit of Korean Application No. 2004-56258, filed on Jul. 20,2004, which are hereby incorporated by reference as if fully set forthherein.

FIELD OF THE INVENTION

The present invention relates to a drum type washing machine, and moreparticularly, to a drum type washing machine in which a tub is directlyconnected to a cabinet, and a drum in the tub and a motor for rotatingthe drum are supported in the cabinet by a suspension, and a bearinghousing structure thereof.

DESCRIPTION OF THE RELATED ART

A conventional drum type washing machine, as shown in FIG. 1, includes arectangular box-shaped cabinet 1, in which a door 2 is installed to thefront side thereof, a tub 3 disposed in the cabinet in the horizontaldirection to accommodate washing water, a spring 5 and a damper 6 forsupporting the tub 3 in the cabinet 1 and for buffering shock, a drum 8rotatably installed in the tub 3 for washing laundry, and a motor 10installed at the rear side of the tub 3 to rotate the drum 8.

In FIG. 1, reference numeral 21 is assigned to a gasket for preventingthe washing water from leaking between the cabinet and the tub, andreference numerals 23 and 25 are assigned to a water supply and a draindevice, respectively.

FIG. 2 is a partially sectional perspective view of the portion “A” inFIG. 1, and illustrates a structure in which the motor 10 is installedat the rear sides of the drum and the tub 3.

Between the motor 10 and the drum 8, a rotation shaft 12 fortransmitting rotary power is installed to connect the motor 10 with thedrum 8, and the drum 10 includes a hub 13 installed at the rear sidethereof, to which the rotation shaft 12 is connected.

The tub 3 includes a bearing housing 14, installed at the rear side ofthe tub 3, through which the rotation shaft 12 penetrates, and a bearing15 for supporting the rotation shaft 12 is installed in the bearinghousing 14.

Here, the bearing housing 14 is made of steel or aluminum, such thatstiffness sufficient to support the rotation shaft 12 can be maintained,and is fixed to the rear side of the tub 3 via insert molding. Thebearing 15 is fixed in the bearing housing 14 by being compulsorilytightly fitted against the bearing housing 14.

The motor 10 is an abduction motor in which a stator 10S is positionedat the center of the motor 10 and a rotor 10 r is positioned around thestator 10S, wherein the stator 10S is assembled with and fixed to thebearing housing 14 by bolts 17 and the rotor 10R is fixed to the end ofthe rotation shaft 12.

However, in the conventional drum type washing machine as describedabove, since the drum 8 and the motor 10 are supported by the tub 3, thetub 3 is supported in the cabinet 1 by the spring 5 and the damper 6, apredetermined space between the cabinet 1 and the tub 3 is required.Thus, there is also a limit to increase the size of the drum 8performing washing process in the cabinet 1 with a predetermined volume.

Moreover, in the conventional drum type washing machine, since the drum8, the bearing 15, and the motor 10 are vibrated together with the tub3, reaction force is generated by the bearing in proportion to thevibration, and a metal bearing housing 14 is fixed to the tub 3 viainsert molding to securely fix the bearing 15 to the tub 3.

However, since sizes of the tub 3 and the bearing housing 14 must bechanged when volume of the conventional drum type washing machine ischanged, the tub 3 and the bearing housing 14 cannot be used in common,and a tub 3 and a bearing housing 14 with different sizes must bemanufactured.

SUMMARY OF THE INVENTION

Therefore, the present invention has been made in view of the aboveand/or other problems, and it is an object of the present invention toprovide a drum type washing machine in which a tub is directly installedin a cabinet and vibration elements such as a drum and a motor aredirectly supported in the cabinet by a suspension such that there is noneed for a separate clearance between the cabinet and the tub, causingan increase in the size of the drum to maximize volume of the drum typewashing machine.

It is another object of the present invention to provide a drum typewashing machine in which defective parts are conveniently repaired orreplaced when a tub or a bearing housing malfunctions, by installing thebearing housing separately from the tub without fixing the bearinghousing to the tub by the insert-molding, and only one of the tub andthe bearing housing, which is not applicable to the drum type washingmachine having the changed washing capacity, is selectively replaced.Thus parts can commonly used in various drum type washing machine havingdifferent volume.

In accordance with the present invention, the above and other aspectscan be accomplished by the provision of drum type washing machineincluding a tub installed in a cabinet, a drum, disposed in the tub, inwhich washing is performed, a motor disposed at the rear side of the tubto rotate the drum, bearing housings disposed between the drum and themotor and respectively having bearings to support a rotation shaft, asuspension connected to the bearing housings and the cabinet to mitigatevibration generated during the rotation of the drum, a bracket installedto the front sides of the bearing housings to form the rear side of thetub, and a gasket installed between the bracket and the tub to seal thetub and to prevent vibration from being transmitted from the bracket tothe tub.

Preferably, the tub is fixed to the cabinet such that the front side ofthe tub is attached to the inner surface of the cabinet.

The bearing housings includes a main bearing housing fixed to thebracket, and a sub-bearing housing, coupled to the rear side of the mainbearing housing, to which a stator of the motor is fixed.

The main bearing housing and the sub-bearing housing are convex inopposite directions such that the central portions of the main bearinghousing and the sub-bearing housing, through which the rotation shaftpenetrates, are spaced apart from each other.

The main bearing housing and the sub-bearing housing are made of pressedmetal plates.

The main bearing housing has a semi-circular upper side higher than apart through which the rotation shaft penetrates, and a rectangularlower side lower than the part through which the rotation shaftpenetrates.

Preferably, the sub-bearing housing is circular.

The suspension is connected to the main bearing housing.

The bracket includes a seal member, installed at the intermediateportion thereof, for preventing washing water from leaking between thebracket and the rotation shaft.

The another object of the present invention is achieved by the provisionof a structure of bearing housings (76 and 78) of a drum type washingmachine including a rotation shaft penetrating through a tub to connecta drum and a motor for driving the drum, a main bearing housing fixed toa portion for forming the rear side of the tub to support a rotationshaft of the motor, a sub-bearing housing coupled with the rear side ofthe main bearing housing to support the rotation shaft.

The main bearing housing and the sub-bearing housing are convex inopposite directions such that the central portions of the main bearinghousing and the sub-bearing housing, through which the rotation shaftpenetrates, are spaced apart from each other.

Preferably, the main bearing housing and the sub-bearing housing aremade of pressed metal plates.

The bearing housings are supported on a cabinet forming the outerappearance of the drum type washing machine by a suspension to mitigatevibration generated during rotation of the drum.

The another object of the present invention is achieved by the provisionof a drum type washing machine including a tub directly fixed in acabinet, a drum, disposed in the tub, in which washing is performed, amotor disposed at the rear side of the tub to rotate the drum, a mainbearing housing fixed to a portion for forming the rear side of the tubto support a rotation shaft of the motor, a sub-bearing housing coupledwith the rear side of the main bearing housing to support the rotationshaft, and a suspension connected to the main bearing housing and thecabinet to mitigate vibration generated during the rotation of the drum.

Moreover, in the drum type washing machine according to the presentinvention, since the bearing housing is separated from the tub insteadof being fixed to the tub by the insert molding, when one of the tub andthe bearing housing malfunctions, only the malfunctioning component mustbe replaced. According to the present invention, when either the tub orthe bearing housing of a drum type washing machine malfunctions, themalfunctioning component may be replaced using a drum or bearing housingdesigned for a drum type machine of a different volume. Thus, the partsare interchangeable among drum type washing machines with differentvolumes.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects and advantages of the present invention willbecome apparent and more readily appreciated from the followingdescription of the embodiments, taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a sectional elevation view illustrating an inner structure ofa conventional drum type washing machine;

FIG. 2 is a partially sectional perspective view of a portion “A” inFIG. 1;

FIG. 3 is a sectional elevation view illustrating an inner structure ofa drum type washing machine according to a preferred embodiment of thepresent invention;

FIG. 4 is a partially sectional perspective view illustrating main partsof the drum type washing machine according to the preferred embodimentof the present invention;

FIG. 5 is a perspective view illustrating main parts of the drum typewashing machine according to the preferred embodiment of the presentinvention; and

FIG. 6 is a rear side view of a bearing housing installed in the drumtype washing machine according to the preferred embodiment of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the preferred embodiments of the drum type washing machineaccording to the present invention will be described in detail withreference to the accompanying drawings.

Although several embodiments of the drum type washing machines arepossible according to the present invention, hereinafter, only the drumtype washing machine according to the preferred embodiment of thepresent invention will be described.

FIGS. 3 to 6 are views illustrating the drum type washing machineaccording to the preferred embodiment of the present invention; FIG. 3is a sectional elevation view illustrating an inner structure of thedrum type washing machine according to the preferred embodiment of thepresent invention, FIG. 4 is a partially sectional perspective viewillustrating main parts of the drum type washing machine according tothe preferred embodiment of the present invention, FIG. 5 is aperspective view illustrating main parts of the drum type washingmachine according to the preferred embodiment of the present invention,and FIG. 6 is a rear side view of a bearing housing.

The drum type washing machine according to the preferred embodiment ofthe present invention, as shown in FIG. 3, includes a rectangularbox-shaped cabinet 50 and a tub 55 directly connected to and installedin the cabinet 50 to accommodate washing water. In other words,although, in the conventional drum type washing machine, a tub isconnected to a cabinet by a spring and a damper, but in the drum typewashing machine according to the preferred embodiment of the presentinvention, the tub 55 is directly fixed to the cabinet 50 without needfor a damper.

As such, a drum 60, in which the tub 55 is directly installed and thelaundry is washed, and vibration elements, such as a motor 66 forrotating the drum 60, are supported in the cabinet 50 by a suspension90, such that vibration generated when the drum 60 is rotated can bereduced.

Especially, the drum 60 is connected to the motor 66 by a rotation shaft69 and is rotated by the motor 66. Between the drum 60 and the motor 66,a bearing housing 75 including bearings 71 and 72 for supporting therotation shaft 69, is installed. The suspension 90 is connected to thebearing housing 75 such that the vibration elements, such as the drum60, the motor 66, and the like, are supported in the cabinet 50 by thebearing housing 75.

In front of the bearing housing 75, a bracket 80 is provided to form therear side of the tub 55, and a gasket 85 installed between the bracket80 and the rear portion of the tub 55 is installed to prevent vibrationfrom being transmitted from the vibration elements to the tub 55 and toprevent water accommodated in the tub 55 from leaking.

Main parts of the drum type washing machine according to the preferredembodiment of the present invention, structured as described above, willbe described as follows.

Preferably, the cabinet 50 takes the shape of a rectangular containerlike that of the conventional drum type washing machine, and has a door52 installed at the front side thereof to open and close the tub 55.

The tub 55 includes a tub main body 56 directly fixed to the front sideof the cabinet 50, and a ring-shaped tub cover 57, which is installed atthe rear side of the tub main body 56 and includes an intermediate partwhere the bracket 80 and the rear gasket 85 are positioned.

The drum 60 is supported, by connecting the rear part of the drum 60 tothe rotation shaft 69, and has a hub 65 to which the rotation shaft 69is connected. The drum 60 includes a plurality of lifts 63 installed atthe inner side thereof to raise and release the laundry in the drum 60.The drum 60 further includes balancers 61 and 62 installed at the frontand rear sides of the drum 60 to balance the drum 60 during the rotationof the drum 60.

The motor 66 is an abduction motor and is mounted at the rear side ofthe bearing housing 75 such that a stator 67 is coupled with the bearinghousing 75 by bolts and a rotor 68 is coupled with the rotation shaft 69by bolts.

Especially, the bearing housing 75, as shown in FIG. 5, includes a mainbearing housing 76 in which the bracket 80 is fixed, and a sub-bearinghousing 78 smaller than the main bearing housing 76 and coupled with therear side of the main bearing housing 76 by bolts, in which the motor 66is fixed.

Here, the main bearing housing 76 has a semi-circular upper side higherthan a part through which the rotation shaft 69 penetrates, and arectangular lower side lower than the part through which the rotationshaft 69 penetrates such that damper brackets 91 and 92 of thesuspension 90 are connected to the lower side.

The circular sub-bearing housing 78 is similar in size to the stator 67of the motor 66.

The main bearing housing 76 and the sub-bearing housing 78 are convex inopposite directions to form a predetermined space therebetween. Thus,since the central portions of the bearing housings 76 and 78, throughwhich the rotation shaft 69 penetrates, are spaced apart from eachother, the two bearings 71 and 72, which are tightly fitted against thecentral portions of the bearing housings 76 and 78, are fixed at apredetermined distance. Moreover, the bracket 80 and the stator 67 ofthe motor 66 closely contact and are fixed to the convex portions 76 aand 78 a of the bearing housings 76 and 78 by bolts, respectively.

The bearing housing 75 is preferably manufactured by drawing the convexportions 76 a and 78 a using a steel plate press.

Next, the bracket 80 is made of non-oxidizable synthetic resin andprevents water from entering the bearing housing 75 through the frontside of the bearing housing 75. The bracket 80 includes a water seal 83,installed at the intermediate portion thereof and serving as a sealmember, for preventing washing water from leaking between the bracket 80and the rotation shaft 69.

The bracket 80 includes a plurality of radial shaped or lattice-shapedribs 81 to reinforce the bracket 80 and bolt holes 82 to couple thebracket 80 to the bearing housing 75 using bolts.

In FIG. 6, reference numeral 75 a is assigned to bolt holes,communicated from the bolt hole of the main bearing housing 76 and thesub-bearing housing 78 to bolt holes 82 of the bracket 80, through whichbolts are fastened, and reference numeral 75 b is assigned to bolt holesto couple the stator 67 using bolts, and reference numeral 75 c isassigned to couple damper brackets 91 and 92 using bolts.

Meanwhile, in the suspension 90, dampers 93 and 95 are installed betweenthe damper brackets 91 and 92 connected to the main bearing housing 76and a base of the cabinet 50, in which a main damper 93, positionedbetween the damper bracket 91 and the damper 95 as seen in FIG. 3,between the damper brackets 91 and 92 and the base of the cabinet 50, isinstalled at an angle, and sub-dampers 95, positioned at both sides ofthe main damper 93, are vertically installed to absorb vibrationgenerated by the vibration elements.

Operation of the drum type washing machine having the structure asdescribed above according to the preferred embodiment of the presentinvention will be described as follows.

According to the drum type washing machine in accordance with thepreferred embodiment of the present invention, since the tub 55 isdirectly installed to the cabinet 50, the size of the tub 55 can beincreased when the cabinet 50 has the same volume as that of the cabinetin the conventional drum type washing machine. Thus, since the drum 60installed in the tub 55 can also be relatively increased in size, thewashing capacity of the drum type washing machine according to thepreferred embodiment of the present invention can be increased withoutincrease of the size of the cabinet 50.

The assembly of the drum type washing machine according to the preferredembodiment of the present invention will be described with respect tothe bearing housing 75 as follows. First, the main bearing housing andthe sub-bearing housing 78, in which the bearings 71 and 72 arerespectively installed, contact each other and are assembled by bolts.

The bracket 80, in which the water seal 83 is installed, is coupled withthe front side of the assembly of the main bearing housing 76 by bolts,and the stator 67 of the motor 66 is coupled with the rear side of thesub-bearing housing 78 by bolts.

As such, after assembling the bracket 80, the bearing housing 75, andthe stator 67, the rotation shaft 69 connected to the hub 62 of the drum60 penetrates the water seal 83 of the bracket 80, the bearings 71 and72 of the bearing housing 75, and the stator 67, and then the rotor 68is coupled with an end of the penetrating rotation shaft 69.

Meanwhile, after the suspension 90 is connected to the bearing housing75, the drum 60 is inserted into the rear side of the tub 55 directlyfixed to the cabinet 50 and the suspension 90 is fixed to the base ofthe cabinet 50, so that the bracket 80, the bearing housing 75, and themotor 66, which are coupled with the drum 60, are installed in thecabinet 50.

Subsequently, the tub 55 and the bracket 80 are connected to each othervia the gasket 85 so that assembly of the main parts of the drum typewashing machine according to the preferred embodiment of the presentinvention is completed.

In the assembly of the drum type washing machine according to thepreferred embodiment of the present invention as described above, sincethe bearing housing 75 is not installed to the tub by insert-molding,but can be separated from the tub, the bearing housing 75 can beinstalled in a drum type washing machine having a difference volume.

Moreover, since the bracket 80 is made of synthetic resin includingplastic and is installed to the front side of the metal bearing housing75 such that the bracket 80 and the gasket 85 form the rear side of thetub 55, the bearing housing 75 is not easily eroded due to water evenafter extended use. Since the water seal 83 is installed at theintermediate portion of the bracket 80, water is prevented from leakingso that the bearings 71 and 72 and the bearing housing 75 are preventedfrom being damaged.

As described above, according to the drum type washing machine of thepresent invention, since the tub is directly installed to the cabinetand the vibration elements, such as the drum, the motor, and the like,are supported on the cabinet by the suspension, volumes of the tub andthe drum can be easily increased and the tub and the drum having theincreased volumes can be installed in the cabinet without increasing thevolume of the cabinet.

Moreover, in the drum type washing machine according to the presentinvention, since the bearing housing is separated from the tub insteadof being fixed to the tub by the insert molding, when one of the tub andthe bearing housing malfunctions, only the malfunctioning component mustbe replaced. According to the present invention, when either the tub orthe bearing housing of a drum type washing machine malfunctions, themalfunctioning component may be replaced using a drum or bearing housingdesigned for a drum type machine of a different volume. Thus, the partsare interchangeable among drum type washing machines with differentvolumes.

Although the preferred embodiments of the present invention have beendisclosed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the scope and spirit of the inventionas disclosed in the accompanying claims.

The present disclosure relates to subject matter contained in KoreanApplication No. 10-2004-0056258, filed on Jul. 20, 2004, the contents ofwhich are herein expressly incorporated by reference in its entirety.

What is claimed is:
 1. A drum type washing machine, comprising: a tubthat receives water therein; a drum rotatably placed in the tub; a driveassembly comprising a rotational shaft connected to the drum, a bearinghousing made of metal so as to rotatably support the rotational shaft,and a motor to rotate the rotational shaft; a first material positionedso as to prevent water inside the tub from contacting a surface of thebearing housing that faces the inside of the tub;, wherein a corrosionresistance of the first material to water is greater than that of thesurface of the bearing housing; a second material positioned so as toprevent water inside the tub from leaking toward the drive assembly andto allow the drive assembly to move relative to the tub; and asuspension unit attached to the bearing housing so as to reducevibration of the drum and the driving assembly.
 2. The washing machineas claimed in claim 1, wherein the first material is a non-metallicmaterial.
 3. The washing machine as claimed in claim 1, wherein thesecond material is flexible, and wherein a first end of the secondmaterial is fastened to the first material.
 4. The washing machine asclaimed in claim 3, wherein a radially outside portion the firstmaterial is bent away from the drum and the first end of the secondmaterial is fastened to the bent portion of the first material.
 5. Thewashing machine as claimed in claim 3, wherein the bearing housingextends beyond an inner circumferential edge of the second material in aradial direction.
 6. The washing machine as claimed in claim 5, whereinthe suspension unit is connected to the bearing housing at a locationwhich is radially outside the inner circumferential edge of the secondmaterial.
 7. The washing machine as claimed in claim 6, wherein thesuspension unit comprises a plurality of dampers and a plurality ofbrackets.
 8. The washing machine as claimed in claim 3, wherein a backsurface of the tub has an opening formed therein, the opening having anedge that is bent toward an outside of the tub, and wherein a second endof the second material opposite the first end thereof is fastened to thebent edge of the opening formed in the back surface of the tub.
 9. Thewashing machine as claimed in claim 1, wherein rotation of the firstmaterial with respect to a rotational axis of the drum is restricted.10. The washing machine as claimed in claim 9, wherein the firstmaterial is fixed to the bearing housing.
 11. The washing machine asclaimed in claim 10, wherein the first material comprises a non-metallicmaterial that is fixed to the bearing housing by bolts.
 12. The washingmachine as claimed in claim 10, wherein a radial distance from the shaftto a fixing point of the first material is greater than half of adistance from the shaft to a radially outer end of the first material.13. The washing machine as claimed in claim 1, wherein the firstmaterial is configured such that a radially outside portion thereof isspaced farther from the drum than a radially inside portion thereof is.14. The washing machine as claimed in claim 1, wherein the motor iscoaxially connected to the shaft.
 15. The washing machine as claimed inclaim 14, wherein the second material is flexible, and wherein an innerdiameter of the second material is greater than an outer diameter of themotor.
 16. The washing machine as claimed in claim 14, wherein thebearing housing extends beyond the motor in a radial direction.
 17. Thewashing machine as claimed in claim 14, wherein a portion of the firstmaterial is positioned inside the tub.
 18. The washing machine asclaimed in claim 1, wherein the tub is supported more rigidly than thedrum is.
 19. The washing machine as claimed in claim 18, wherein a frontwall of the tub is fixed to a cabinet which defines an exterior of thewashing machine.
 20. A method of providing a drum type washing machinecomprising: providing a tub that receives water therein; providing adrum in the tub so as to receive laundry therein; providing a rotationalshaft which is to be connected to the drum; providing a motor which isto rotate the shaft; providing a metallic bearing housing which is torotatably support the shaft; treating a tub-side surface of the metallicbearing housing with a first material to prevent water inside the tubfrom contacting the tub-side surface, a corrosion resistance of thefirst material to water being greater than that of the tub-side surfaceof the bearing housing; positioning a flexible material so as to preventwater inside the tub from leaking rearward and to allow the drum tovibrate relative to the tub; and attaching a suspension unit to thebearing housing to reduce vibration of the drum.
 21. A drum type washingmachine, comprising: a cabinet; a tub directly connected to the cabinetso as to receive water therein; a drum rotatably positioned in the tub;a drive assembly comprising a rotational shaft connected to the drum, abearing housing made of a metal material to rotatably support therotational shaft, and a motor to rotate the rotational shaft; a firstmaterial positioned so as to prevent water inside the tub fromcontacting a surface of the bearing housing that faces the inside of thetub, wherein a corrosion resistance of the first material to water isgreater than that of the surface of the bearing housing; a second,flexible material positioned so as to prevent water inside the tub fromleaking toward the driving assembly and to allow the drive assembly tomove relative to the tub; and a suspension unit that reduces vibrationof the drum and the drive assembly.
 22. A method of providing a drumtype washing machine, comprising: directly connecting a tub to acabinet; rotatably positioning a drum in the tub; connecting arotational shaft to the drum, the rotational shaft being connected to amotor that provides a rotational force to the rotational shaft;rotatably supporting the rotational shaft in a metallic bearing housing;treating a tub-side surface of the metallic bearing housing with a firstmaterial to prevent water inside the tub from contacting the tub-sidesurface, a corrosion resistance of the first material to water beinggreater than that of the tub-side surface of the metallic bearinghousing; positioning a second, flexible material so as to prevent waterinside the tub from leaking rearward and allow the drum to vibraterelative to the tub; and providing a suspension unit to reduce vibrationof the drum.